Stamped power contact

ABSTRACT

A power port terminal formed by stamping from a blank of conductive material comprises a contact receiving socket portion ( 12 ) and an integral mounting portion ( 14 ). The socket includes a web with a plurality of beams ( 20 ) thereon. The inner surface of the beams on the bends thereof define a substantially continuous cylindrical contact surface at a predetermined point along the reference axis of the terminal. The contact surface has a predetermined constricted dimension ( 36 ) measured in a plane perpendicular to the reference axis, this dimension being the most constricted dimension along the reference axis of the terminal. The terminal is thereby able to accommodate a pin of any desired axial length. The trailing mounting legs ( 46 ) thereon, that in the preferred instance, extend generally perpendicular to the reference axis of the terminal. Latch tabs ( 38 ) may be provided on one or more of the beams. There are lateral projections ( 62 ) on the mounting portion, which restrain the terminal from pivoting on its longitudinal axis when it is mounted in a through hole ( 52 ) in an insulative housing ( 50 ).

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a socket-type terminal for use ineffecting a relatively high-amperage power connection with a male pin ofany desired length.

2. Brief Description of Prior Developments

A power port terminal for interconnecting a backplane with a male pinplug may be formed in any one of a variety of ways. U.S. Pat. No.4,702,707 illustrates a power terminal that includes a base to which amating component having a socket may be attached. In this terminal thebase and a portion of the mating component are formed as screw machinedparts. U.S. Pat. No. 4,749,357 shows a power connector in which a socketdefined from a crown band of spring contact beams is inserted into ablock of conductive material. In both of these arrangements the contactbeams of the terminal extend around the entire 360° periphery of themale pin. However, since one end of the terminal is closed, the socketmay accept a pin having only a predetermined limited axial dimension.

The power terminal shown at page 334, 335 of the Du Pont ElectronicsInterconnect and Packaging Catalog, August 1988, is also a machined parthaving a socket that may accept a pin having only a predeterminedlimited axial dimension. This part also includes a snapring latcharrangement which is received about the socket of the terminal and whichcooperates with a housing to retain the terminal.

The terminal shown in U.S. Pat. No. 4,002,400, assigned to the assigneeof the present invention, is formed from a stamped blank of conductivematerial. Again, however, it appears that the socket portion of theterminal is blocked at an axially rearward point by a wire crimp barreland an insulation crimp barrel, effectively limiting the axial dimensionof a pin receivable in the socket.

The power terminal forming a part of the Du Pont HPC Connector System,as shown at page 6 of Bulletin 7121, January 1987, is fabricated from astamped blank of conductive material. Although in this terminal thelength of the pin receivably by the socket is not limited, the socketregion does not fully surround the pin when the same is receivedtherein.

U.S. Pat. 5,376,012, the contents of which are incorporated herein byreference, discloses a power port terminal which is formed by stampingfrom a blank of conductive material. The socket includes a web with aplurality of beams. The inner surface of the beams define asubstantially continuous cylindrical contact surface. The trailingmounting portion has a set of mounting legs. While this contact providesa socket formed from a stamped conductive material that both surrounds amale pin over substantially 360° of its periphery and does not limit theaxial length of pin receivable therein, it has been found that thiscontact may tend to pivot on its longitudinal axis when it is mounted ina through hole of an insulative housing.

A need, therefore, exists for a stamped power contact which does notpivot on its longitudinal axis. A need also exists for such a stampedpower contact which is not subject to being overextended into thethrough hole of the insulative housing in which it is mounted.

SUMMARY OF THE INVENTION

The present invention relates to a power port terminal formed bystamping from a blank of conductive material. The terminal comprises acontact receiving socket portion and an integral mounting portion. Theterminal has a reference axis extending therethrough. The contactreceiving socket portion includes a web with a plurality of beamsthereon. When the terminal is formed the beams cooperate to form anaxially extending tubular socket region. The inner surface of the beamson the bends thereof define a substantially continuous cylindricalcontact surface at a predetermined point along the reference axis withinthe tubular region. The contact surface is interrupted only by thespacing between the beams and is thus adapted to surround a male pinover 360° of its periphery. The cylindrical contact surface has apredetermined constricted dimension measured in a plane perpendicular tothe reference axis, this dimension of the substantially continuouscylindrical contact surface being the most constricted dimension alongthe reference axis of the terminal. The terminal is thereby able toaccommodate a pin of any desired axial length.

The trailing mounting portion has a set of mounting legs thereon. Themounting legs depend from the lateral flanges of a curved hood portion.The hood and flanges preferably surround substantially 270° of theperiphery of the pin. In the preferred instance the mounting legs extendgenerally perpendicular to the reference axis of the terminal. Lateralprojections also depend from the hood to restrain the terminal frompivoting about its longitudinal axis.

One or more of the beams may have a latch tab thereon. The latch tabsengage with ribs provided in the terminal housing to secure the terminaltherewithin.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood from the following detaileddescription thereof taken in connection with the accompanying drawings,which form a part of this application and in which:

FIG. 1 is a side elevational view of a preferred embodiment of theterminal of the present invention;

FIG. 2 is a top plan view of the terminal shown in FIG. 1;

FIG. 3 is a front end view of the terminal shown in FIG. 1;

FIG. 4 is a rear end view of the terminal shown in FIG. 1;

FIG. 5 is a bottom plan view of the terminal shown in FIG. 1 as insertedin an insulative housing;

FIG. 6 is a side elevational view of the contact and housing shown inFIG. 5 wherein the housing is in vertical cross section; and

FIG. 7 is a front end view of the housing and contact shown in FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Throughout the following detailed description similar reference numeralsrefer to similar elements in all figures of the drawings.

With reference to FIGS. 1 and 2 shown is a power port terminal generallyindicated by reference character 10 in accordance with the presentinvention. The terminal 10 is formed by stamping from a blank of asuitable conductive material, such as beryllium copper material. Adeveloped view of the blank is illustrated in FIG. 6. The terminal 10includes a contact receiving portion 12 and an integral mounting portion14. A reference axis 10A extends through the terminal 10.

The contact receiving portion 12 includes a web 16 from which extend aplurality of beams, or fingers, 20. The beams are preferablyequiangularly arranged about the axis 10A. In the embodiment illustratedfive beams 20 are shown, each beam being angularly separated from theangularly adjacent beam by a gap 20G . When the terminal 10 is fullyformed (in a manner to be described) each of the beams 20 has a curvedinside surface 20S with a lip 20B or alternatively an inward bendlocated axially therealong.

The beams 20 cooperate to form an axially extending tubular socketregion 26. The socket region 26 is thus adapted to surround a male pinguided therein over 360° of its periphery. The inner surface 20S of thebeams 20 define a substantially continuous cylindrical contact surface28 lying at a predetermined point 30 along the reference axis 10A withinthe tubular socket region 26. The contact surface 28 is, as may be bestseen in FIGS. 3 and 4, interrupted only by the gap 20G between angularlyadjacent beams 20.

The cylindrical contact surface 28 defined by the lips 20B of each beam20 defines a circle centered on the reference axis 10A of the terminal.The surface 28 thus imparts a predetermined constricted dimension 36(i.e., the diameter of the surface 28) measured in a plane perpendicularto the reference axis 10A. This dimension 36 of the substantiallycontinuous cylindrical contact surface 28 is the most constricteddimension along the reference axis 10A of the terminal. The through boreof the socket region 26 of the terminal 10 is thus effectivelyunlimited. The terminal 10 is thereby able to accommodate a pin of anydesired axial length.

In the preferred embodiment two of the beams 20 are provided with latchtabs 38. As may be seen in FIG. 3 the tabs 38 extend outwardly beyondthe basic outer diametric dimension of the contact receiving portion 12.As an alternative it should be understood that only a single latch tabor more than two latch tabs may be provided as desired. The tabs 38 maybe conveniently located on any of the beams 20. In the preferredarrangement the tab(s) 38 are formed as appendages disposed axiallybetween the laterally outward beam(s) 20 and the mounting portion 14.The tabs 38 may be additionally or alternately formed by punchingthrough the material of the web 16.

The trailing mounting portion 14 extends rearwardly from the web 16. Themounting portion 14 includes a hood region 40 melding into a pair oflateral flanges 42. As is best seen in FIG. 4 and 5 the hood 40 and theflanges 42 preferably extend substantially 270° about the reference axis10A of the terminal 10. A plurality of mounting legs 46 depending fromeach flange 42 defines a set of mounting legs for the terminal 10. Themounting legs 46 each extend downwardly a substantial distance below thecontact receiving portion 12.

In the preferred embodiment, the mounting legs extend generallyperpendicularly to the reference axis 10A of the terminal. The mountinglegs 46 may be received by plated through bores provided in the surfaceof a substrate whereby electrical interconnection may be effectedbetween the terminal 10 and a backplane on the substrate. It should beunderstood that is within the contemplation of the present invention toarrange the legs 46 such that they align parallel to the reference axis10A of the terminal.

The terminal 10 would preferably be formed from a blank (not shown). Theblank is attached to a carrier strip (not shown) by a tail (not shown).The blank is made by a stamping operation and the terminal 10 is formedtherefrom by bending the blank over a mandrel, as is understood by thoseskilled in the art.

With reference to FIGS. 5-7 the terminal 10 is received within a housing50 formed from a block of a suitable insulating material. The housing 50has a through passage 52 therein. Locating guide members 54 extendaxially along the walls of the passage 52 to position the terminal 10within the housing. Locking ribs 56 are disposed about the rear end ofthe through hole 52. The terminal 10 is inserted into the passage 52 inthe housing 50 in the direction of the arrow 58. The latches 38 on thebeams 20 are resiliently deflected as the terminal 10 is inserted intothe housing 50. Once axially past the locking ribs 56 the latches 38snap into locking position behind the locking ribs 56. Thecircumferential extend of the locking ribs 56 is such that the tabs 38will engage against a rib 56 to retain the terminal 10, once inserted,within the housing 50.

Since the dimension 36 of the surface 28 is the most constricteddimension of the socket, a terminal 10 in accordance with the presentinvention presents no impediment to the axial advance of a male pin.Thus a pin having any desired length may be received coaxially with thereference axis of the terminal. Such a capability is believedadvantageous when using the terminal of the present invention in aso-called “first make-last break” interconnection system.

Referring to FIGS. 1-4 and 6, resilient lateral projections 60 extendfrom the hood 40 of the mounting portion 14. To the rear of theselateral projections 60 there are appendages 62. Referring particularlyto FIG. 6, it will be seen that the resilient lateral projections 60engage locking ribs 56. It will be understood that the lateralprojections 60 on the opposed sides the opposed sides of the terminal 10each engage a locking rib 56 so as to prevent or significantly reducepivotal motion of the terminal 10 in the through hole 52 of theinsulative housing 50. It will also be appreciated that the appendages62 extend outwardly from the lateral projections 60 so as to abut therear of the insulative housing and prevent the terminal 10 from beingoverextending into the though hole 52.

It will be appreciated that a stamp power contact has been describedwhich is not subject to undo pivoting motion in the through hole of aninsulative housing in which it is mounted. It will also be appreciatedthat this stamp power contact is not subject to being overextended intothe through hole of the insulative housing.

While the present invention has been described in connection with thepreferred embodiments of the various figures, it is to be understoodthat other similar embodiments may be used or modifications andadditions may be made to the described embodiment for performing thesame function of the present invention without deviating therefrom.Therefore, the present invention should not be limited to any singleembodiment, but rather construed in breadth and scope in accordance withthe recitation of the appended claims.

What is claimed is:
 1. A female-type power port terminal for connectingto a male plug of a wide range of lengths and cross-sectionaldimensions, comprising: a contact receiving portion having a web and aplurality of fingers that are unitary with said web, said fingers beingarranged to form an axially extending socket that is aligned about areference axis, each of said fingers having a free end that is distalfrom said web, said free ends being unconnected to each other exceptthrough said web, each of said fingers being angled towards thereference axis with said free end inwards from said web, said fingerstogether defining a contact surface that is constructed and arranged tocontact the male plug that is inserted into said socket, said contactsurface being most constricted along said reference axis in saidterminal at a point proximate the free ends of the fingers; and amounting portion that is unitary with and extends longitudinally fromsaid contact receiving portion and is formed together with said contactreceiving portion from a single blank of conductive material, saidmounting portion comprising a hood region that is curved about saidreference axis by substantially 270 degrees to define a space that iscoextensive and aligned with said socket, said hood region being open atleast to permit a plug to pass into said space, said mounting portionfurther comprising a plurality of mounting legs thereon for mounting theterminal on a substrate; whereby said terminal, as a result of saidunconnected free ends, is constructed to accept different male plugswithin a wide range of cross-sectional dimensions, and, as a result ofsaid open space defined by said hood region, is constructed to acceptdifferent male plug having a wide range of lengths and wherein said hoodregion has at least one lateral projection projecting laterally outwardsfrom the hood region and ending in a free edge that is distal to thehood region.
 2. The power port terminal of claim 1 wherein at least oneof the fingers has a latch tab thereon.
 3. The power port terminal ofclaim 1 wherein at least two of the fingers has a latch tab thereon. 4.The power port terminal of claim 1 wherein at least one of the fingershas a latch tab thereon.
 5. The power port terminal of claim 1 whereinat least two of the fingers has a latch tab thereon.
 6. The terminal ofclaim 1 wherein the hood region has another lateral projectionprojecting from the hood region and forming with the at least onelateral projection a pair of opposed lateral projections on the hoodregion.
 7. The terminal of claim 1 wherein the at least one lateralprojection extends downwardly from the hood region.
 8. The power portterminal of claim 1 wherein the mounting legs extend generallyperpendicularly to the reference axis.
 9. The power port terminal ofclaim 8 wherein at least one of the fingers has a latch tab thereon. 10.The power port terminal of claim 8 wherein at least two of the fingershas a latch tab thereon.
 11. The terminal of claim 1 wherein theterminal is mounted in a through hole in an insulative housing.
 12. Theterminal of claim 11 wherein there is at least one rib in the throughhole of the insulative housing and the at least one lateral projectionengages said at least one rib.
 13. The terminal of claim 11 wherein theat least one lateral projection has an appendage depending from thedistal edge of the at least on lateral projection, which appendageprevents the terminal from being over extended in the through hole. 14.A female-type power port terminal for connecting to a male plug of awide range of lengths and cross-sectional dimensions, comprising: acontact receiving portion having a web and a plurality of fingers thatare unitary with said web, said fingers being arranged to form anaxially extending socket that is aligned about a reference axis, each ofsaid fingers having a free end that is distal from said web, said freeends being unconnected to each other except through said web, each ofsaid fingers being angled towards said reference axis with said free endinwards from said web, said fingers together defining a contact surfacethat is constructed and arranged to contact the male plug that isinserted into said socket, said contact surface being most constrictedalong said reference axis in said terminal at a point proximate the freeends of the fingers; and a mounting portion that is unitary with andextends longitudinally from said contact receiving portion and is formedtogether with said contact receiving portion from a single blank ofconductive material, said mounting portion comprising a hood region thatis curved about said reference axis to define a space that iscoextensive and aligned with said socket, said hood region being open atleast to permit a plug to pass into said space and said hood region hasat least one lateral projection projecting laterally outward from thehood region and ending in a free edge that is distal to the hood region;said mounting portion further comprising at least three mounting legsthereon for mounting the terminal on a substrate, said mounting legseach extending downwardly a substantial distance below said contactreceiving portion; whereby said terminal, as a result of saidunconnected free ends, is constructed to accept different male plugswithin a wide range of cross-sectional dimensions, and, as a result ofsaid open space defined by said hood region, is constructed to acceptdifferent male plugs with a wide range of lengths.
 15. The terminal ofclaim 14 wherein the hood region has another lateral projectionprojecting laterally from the hood region and forming with the at leastone lateral projection a pair of opposed lateral projections on the hoodregion.
 16. The terminal of claim 14 wherein the at least one lateralprojection extends downwardly from the hood region.
 17. The terminal ofclaim 14 wherein the terminal is mounted in a through hole of aninsulative housing.
 18. The terminal of claim 17 wherein there is atleast one rib in the through hole of the insulative housing and the atleast one lateral projection engages said at least one rib.
 19. Theterminal of claim 17 wherein the at least one lateral projection has anappendage depending from the distal edge of the at least one lateralprojection, which appendage prevents the terminal from beingoverextended in the through hole.